Transient voltage protection device, material, and manufacturing methods

ABSTRACT

A transient voltage suppression device includes a dielectric layer defining a receptacle for a variable impedance material proximate a gapped electrode. Methods for manufacturing the device and for formulating a variable voltage material at lower cost and with higher manufacturing yields is also provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 11/186,514 filed Jul. 21, 2005, the completedisclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to overvoltage protection devices forprotecting electronic equipment and to methods of making such devices,and more specifically to devices that are commonly referred to as “surgeprotection” or “transient voltage suppression” devices.

Transient voltage suppression devices have been developed in response tothe need to protect the ever-expanding number of electronic devices uponwhich today's technological society depends from high voltages of ashort, or transient duration. Electrical transient voltages can becreated by, for example, electrostatic discharge or transientspropagated by human contact. Examples of electrical equipment whichtypically employ transient voltage protection equipment includetelecommunications systems, computer systems and control systems.

Some known transient voltage suppression devices include a materialhaving a variable impedance that interconnects, for example, a signalconductor pad and a ground conductor pad formed upon a ceramic substrateor printed circuit board substrate materials. Variable impedancematerials, also sometimes referred to as “overstress responsivecompositions” are sometimes fabricated as a mixture of conductive and/orsemiconductive particles suspended as a matrix within a binding materialsuch as an insulative resin. The signal and ground pads are separated bya small gap on the surface of the substrate, and the variable impedancematerial is placed into the gap to interconnect the ground and signalconductors. Through-holes or vias extend through the substrate on eitherend of the device and are plated to provide an electrical path to thesignal and ground pads on the substrate. In a surface mount device, oneof the plated vias may be connected to a signal conductor or trace of acircuit board, and the other of the plated vias may be connected to aground conductor trace of a circuit board. The signal and ground pads ofthe device are therefore connected to signal and ground conductors,respectively, of an electrical system to be protected.

The variable impedance material exhibits a relatively high resistance(sometimes referred to herein as the “off-state”) when the voltageand/or current passing through the signal conductor is within aspecified range, and a relatively low impedance (referred to herein asthe “on-state”) when the voltage and/or current exceeds a predeterminedthreshold. In the on-state, the pulse or transient voltage experiencedby the signal conductor will be shunted through the device to the groundconductor of the electrical system, and the voltage associated with thepulse will be clamped at a relatively low value for the duration of thepulse. The variable impedance material recovers after the voltage orcurrent pulse has passed and returns to its high impedance state.

While such devices can be effective to protect electronic equipment fromtransient pulses, they are subject to a number of manufacturingdifficulties. For example, the ground and signal pads are typicallyformed by etching and photolithographic techniques in which layers ofconductive material are removed from the substrate, sometimes referredto as a subtractive formation process, to form the ground and signalpads. The gap between the ground and signal pads is typically cut ormachined with a laser or other known technique at a separate stage ofmanufacture from the conductor formation, and controlling the gapformation is difficult and expensive.

Additionally, compounding the variable impedance material involves manyprocessing stages and can also be difficult to consistently produce. Dueto the small size of some devices, especially in chip type devices, thevariable impedance material can be difficult to apply to the gap, andproviding termination structure to connect the device to circuitry canbe problematic. Cumulatively, these and other difficulties lead tohigher production costs and decreased manufacturing yields of acceptabledevices in the fabrication process.

It would be desirable to provide a lower cost and more reliablemanufacture of such devices so that transient voltage suppressiondevices may be produced with increased production yields.

BRIEF SUMMARY OF THE INVENTION

According to an exemplary embodiment, a transient voltage suppressiondevice is provided. The device comprises a first dielectric layer, andat least one electrode extending on the first dielectric layer anddefining a conductive path. The electrode includes a gap that interruptsthe conductive path, and a variable impedance material substantiallyfills the gap in the electrode, and a second dielectric layer overliesthe electrode, wherein the electrode is sandwiched between the first andsecond dielectric layers and at least one of the first and seconddielectric layers are formed with at least one opening proximate the gapand defining a receptacle for the variable impedance material.

According to another embodiment, a transient voltage suppression chipdevice is provided. The chip device comprises a first dielectric layer,an electrode extending on the first dielectric layer and including atleast one gap that interrupts a conductive path through the electrode,and a second dielectric layer overlying the electrode, wherein theelectrode is sandwiched between the first and second dielectric layers.The second dielectric layer is formed with an opening overlying the gap,and a variable impedance material is situated in the opening andsubstantially fills the gap in the electrode. The variable impedancematerial exhibits a relatively high impedance when subjected to voltageand/or current up to a predetermined threshold value, and exhibits arelatively low impedance when subjected to voltage and/or current thatexceeds the predetermined threshold. A third dielectric layer overliesthe second layer and closes the opening in the second dielectric layer,and surface mount terminations establish a conductive path to theelectrode on either side of the gap.

According to still another embodiment, a transient voltage suppressiondevice comprises first and second dielectric layers each defining atleast one variable impedance opening therein, and at least one electrodeextending between the first dielectric layer and including at least onegap that interrupts a conductive path through the electrode. Theelectrode is an electroformed foil formed independently of the first andsecond dielectric layers and integrally formed with the gap, and theelectrode is sandwiched between the first and second dielectric layers.The variable impedance openings of the first and second dielectriclayers are positioned proximate the gap, and the third and fourthdielectric layers are situated on the first and second dielectriclayers, respectively, wherein the third and fourth layers close theopenings in the first and second dielectric layers and the first,second, third and fourth dielectric layers are secured to one another toform a chip structure. A variable impedance material is situated in theopenings of the first and second dielectric layers and substantiallysurrounds the electrode from above and below, and surface mountterminations establish a conductive path to the electrode on either sideof the gap.

A method of manufacturing a transient voltage suppression device is alsoprovided. The method comprises providing a first dielectric layer,forming an electrode with an integrally formed gap according to anadditive formation process, providing a second dielectric layer havingat least one opening formed therein, securing the second dielectriclayer to the first dielectric layer with the opening in the seconddielectric layer overlying the gap, introducing a variable impedancematerial into the opening, and substantially filling the gap in theelectrode with the variable impedance material.

A method of fabricating a variable impedance material is provided aswell. The method comprises mixing conductive particles and solvatedpolymer with insulator particles and filler particles, wherein thefiller particles include an arc quenching material. The mixed materialis vulcanized, thereby providing a material exhibiting a relatively highimpedance when subjected to voltage and/or current up to a predeterminedthreshold value, and exhibiting a relatively low impedance whensubjected to voltage and/or current that exceeds the predeterminedthreshold.

According to still another embodiment, a transient voltage suppressiondevice is provided. The device comprises a first dielectric layer, meansfor providing a gapped conductive path on the first dielectric layer,and means for exhibiting a relatively high impedance through the gappedconductive path when subjected to voltage and/or current up to apredetermined threshold value and exhibiting a relatively low impedancethrough the gapped conductive path when subjected to voltage and/orcurrent that exceeds the predetermined threshold. Means are alsoprovided, secured to the first dielectric layer, for exposing a portionof the gapped electrode for introduction of the means for exhibiting.The means for exposing further confining the means for exhibiting to apredetermined location in the vicinity of the gapped electrode when themeans for exhibiting is introduced to the means for exposing.

A variable impedance material for a transient voltage suppression deviceis also provided. The material comprises a binder, conductive particles,insulator particles, and filler material, wherein the filler materialincludes an arc quenching material. The volume ratio of conductiveparticles to binder is between about 0.5 and 2.0, and the materialcontains no more than about 5% by weight of organic material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a transient voltage suppression deviceaccording to the present invention.

FIG. 2 is an exploded perspective view of the device shown in FIG. 1.

FIG. 3 is a process flow chart of a method of manufacturing the deviceshown in FIGS. 1 and 2.

FIG. 4 is a perspective view of the device shown in FIG. 1 at a firststage of manufacture.

FIG. 5 is a partial sectional view of the device shown in FIG. 1 atanother stage of manufacture.

FIG. 5 a is an elevational view of a portion of FIG. 5.

FIG. 6 is a top plan view of a portion of the device shown in FIG. 1 ata bulk stage of manufacture.

FIG. 7 is a process flowchart for the manufacture of a variableimpedance material for the device shown in FIGS. 1-6.

FIG. 8 is a perspective view of another embodiment of a transientvoltage suppression device.

FIG. 9 is an exploded view of a bulk manufacture of the device shown inFIG. 8.

FIG. 10 is a bottom view of the bulk manufacture shown in FIG. 10 at onestage in the manufacturing process.

FIG. 11 is a sectional view of the device shown in FIG. 8.

FIG. 12 is a process flow chart of a method of manufacturing the deviceshown in FIG. 8.

FIG. 13 is a perspective view of another embodiment of a transientvoltage suppression device according to the present invention.

FIG. 14 is a top plan view of the device shown in FIG. 13 at one stageof manufacture.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a perspective view of a transient voltage suppression device10 in accordance with an exemplary embodiment of the present invention.For the reasons set forth below, the transient voltage suppressiondevice 10 is believed to be manufacturable at a lower cost thanconventional transient voltage suppression device while providing higherproduction yields of satisfactory products.

The transient voltage suppression device 10 may have a layeredconstruction, described in detail below, and includes an electrode 12defining a conductive path enclosed in a number of dielectric layers 14as explained below. The electrode 12 includes a gap (not shown inFIG. 1) that interrupts the conductive path, and a variable impedancematerial, described below, is provided in the gap. The variableimpedance material exhibits a relatively high impedance when subjectedto voltage and/or current up to a predetermined threshold value, andexhibits a relatively low impedance when subjected to voltage and/orcurrent that exceeds the predetermined threshold.

The electrode 12 electrically extends between and is in a conductiverelationship with surface mount terminations 16. The terminations 16, inuse, are coupled to conductors, terminals, contact pads, or circuitterminations of a printed circuit board (not shown). More specifically,one of the terminations 16 may be coupled to a signal conductor, and theother of the terminations 16 may be coupled to a ground conductor. Whenvoltage and or/current current flowing through the signal conductor isbelow a predetermined threshold, the variable impedance material is inthe high resistance state (sometimes referred to herein as the“off-state”) in which substantially no current flows through thevariable impedance material in the electrode gap. Consequently, in theoff state, substantially no current is carried across the electrodebetween the terminations 16, during which time the signal conductor isungrounded.

As the voltage and/or current flowing through the signal conductorapproaches the predetermined threshold, dependant upon characteristicsof the variable impedance material employed in the device 10, thevariable impedance material switches to the low impedance state(referred to herein as the “on-state”). That is, the electricalcharacteristics of the variable impedance material will change such thatmost, if not all, of the current flows through the variable impedancematerial in the electrode gap, and the current flows between theterminations 16 to ground. As such, a pulse or transient voltageexperienced by the signal conductor is be shunted to the groundconductor, and the voltage associated with the pulse may be clamped at arelatively low value for the duration of the pulse. The variableimpedance material recovers after the voltage or current pulse haspassed and returns to its high impedance state. Thus, the signalconductor and associated circuitry can continue normal operation shortlyafter the pulse has ended. In this way, the circuitry associated withthe signal conductor is protected without substantial interruption tothe affected circuitry. Transient voltage and surge protection forcircuitry connected to the device is therefore provided.

In an illustrative embodiment, the transient voltage suppression device10 may have a chip configuration. That is, the device 10 may begenerally rectangular in shape and includes a width W, a length L and aheight H suitable for surface mounting of the device 10 to a printedcircuit board while occupying a small space. For example, L may beapproximately 0.040 to 0.060 inches and W may be approximately 0.020 to0.030 inches, such that the transient voltage suppression deviceoccupies roughly the same area on a circuit board as other electricalchip components, including but not limited to chip fuses, chipresistors, and the like as those in the art may appreciate. H isapproximately equal to the combined thickness of the various layers 12and 14 employed to fabricate the transient voltage suppression device10. Notably, H is considerably less than either L or W to maintain a lowprofile of the transient voltage suppression device 10. It isrecognized, however, that actual dimensions of the device 10 may varyfrom the illustrative dimensions set forth herein to greater or lesserdimensions, including dimensions of more than one inch without departingfrom the scope of the present invention.

FIG. 2 is an exploded perspective view of the transient voltagesuppression device 10 illustrating the various layers 12, 14 employed infabrication of the transient voltage suppression device 10.Specifically, in an exemplary embodiment, the transient voltagesuppression device 10 may be constructed essentially from six layersincluding the electrode 12 sandwiched between a first and seconddielectric layers 20, 22 which, in turn, are sandwiched between thirdand fourth dielectric layers 24, 26. A fifth dielectric layer 28overlies the third dielectric layer 24. As will be appreciated below,the dielectric layers 20, 22, 24, 26 and 28 each serve a distinctpurpose in the device 10, and the materials used to fabricate the layersaccordingly vary from one another.

Unlike known transient voltage suppression devices, the electrode 12 isan electroformed, 3-20 micron thick nickel foil which is fabricated andformed independently from the first and second dielectric layers 20 and22. Specifically, in an illustrative embodiment, the electrode 12 isfabricated according to a known additive process, such aselectro-forming process wherein the desired shape of the electrode layeris plated up, and a negative image is cast on a photo-resist coatedsubstrate (not shown). A thin layer of metal, such as nickel, issubsequently plated onto the negative image cast, and the plated layeris then peeled from the cast to be a free standing foil extendingbetween the first and second dielectric layers 20 and 22. While nickelis believed to be advantageous for its structural strength when peeledfrom the cast, it is contemplated that other metals and conductivecompositions and alloys may likewise be used to form the electrode inanother embodiment of the invention.

As shown in FIG. 2, the electrode 12 is formed in the shape of a capitalI with wider anchor portions 30 and 32 and a relatively narrow pathportion 34 extending between the anchor portions 30 and 32, therebydefining a conductive path between the first and second dielectriclayers 20 and 22. A small gap 36, on the order of several microns in anexemplary embodiment, interrupts the conductive path through the pathportions 34, and the variable impedance material (not shown in FIG. 2)is applied to the gap 36 in the manner explained below to interconnectthe path portions 34 of the electrode 12. Also, termination openings 38are formed into the ends of the anchor portions 30, 32 to provideelectrical connection of the electrode 12 to a circuit board asexplained below. The wider anchor portions accommodate manufacturingtolerances in formation of the openings 38.

Notably, the electrode gap 36 is integrally formed into the image castso that the electroformed electrode is plated with the gap 36 alreadypresent or pre-formed. That is, a separate manufacturing step to formthe gap 36 is avoided, and so are related costs and difficulties ofdoing so, by forming the gap simultaneously with the electrode 12 in theelectroforming process. The gap 36 may be formed centrally in theelectrode 12 as shown in FIG. 2, or may be formed elsewhere within theelectrode 12 if desired. While one particular shape of the electrode 12is illustrated in FIG. 2, it is understood that various other shapes ofthe shapes of the electrode 12 may likewise be employed in otherembodiments.

Separate and independent formation of the electrode 12 allows for otheradvantages as well in comparison to known constructions of transientvoltage suppression devices. For example, separate and independentformation of the electrode 12 permits greater accuracy in the controland position of the electrode layer with respect to the dielectriclayers 20, 22, 24, 26 and 28 when the transient voltage suppressiondevice 10 is constructed. In comparison to etching processes of knownsuch devices, independent formation of the electrode 12 permits greatercontrol over the shape of the conductive path relative to the first andsecond dielectric layers 20, 22. While etching tends to produce obliqueor sloped side edges of the conductive path once formed, substantiallyperpendicular side edges are possible with electroforming processes,therefore providing a more repeatable performance in the triggervoltage, clamping voltage, and leakage current characteristics of themanufactured device 10. Additionally, separate and independent formationof the electrode provides for electrodes having varying thickness in avertical dimension (i.e., perpendicular to the dielectric layers) toproduce vertical profiles or contours in the electrode 12 that can varyperformance characteristics. Still further, multiple metals or metalalloys may be used in the separate and independent formation process,also to vary performance characteristics of the device.

While electroforming of the electrode 12 in a manner separate anddistinct from the first and second dielectric layers 20, 22 is believedto be advantageous, it is understood that the electrode 12 may bealternatively formed by other methods while still obtaining some of theadvantages of the present invention. For example, the electrode 12 maybe an electro deposited metal foil applied to the first dielectric layer20 according to known techniques, including other additive techniquessuch as screen printing and deposition techniques, and subtractivetechniques such as chemical etching and the like as known in the art.

The first dielectric layer 20 underlies the electrode 12 and includes acircular shaped opening 40 underlying a portion of the path portions 34,and in particular, the gap 36, of the electrode 12. Termination openings42 are formed into either end of the first dielectric layer 20.Likewise, the second dielectric layer 22 overlies the electrode 12 andincludes a circular shaped opening 44 overlying a portion of the pathportions 34, and in particular, the gap 36, of the electrode 12.Termination openings 46 are formed into either end of the seconddielectric layer 22.

Notably, and in an exemplary embodiment, the path portions 34 of theelectrode 12 contact a surface of neither of the first and seconddielectric layers 20, 22 in the vicinity of the gap 36. The openings 40,44 in the respective first and second dielectric layers 20, 22 exposethe gap 36 in the electrode and define a receptacle above and below theelectrode gap 36 for the introduction of the variable impedancematerial. That is, the openings 40, 44 provide a confined location forthe variable impedance material in the device 10, and it may beaccordingly be ensured that the variable impedance materialsubstantially surrounds and fills the gap 36 to ensure proper operationof the device 10.

While circular shaped openings 40, 44 are illustrated in the first andsecond dielectric layers 20, 22, it is recognized that other shapes maybe used to form the openings in another embodiment as desired.

In an illustrative embodiment, the first and second dielectric layers20, 22 are each fabricated from a commercially available, 50 micronthick polyimide dielectric film including a 4 micron adhesive film tosecure the layers to one another and to the electrode 12. It isappreciated, however, that in alternative embodiments, other dimensionsof materials may be utilized, and further it is contemplated thatsuitable electrical dielectric and insulation materials (polyimide andnon-polyimide), may be employed. It is also recognized that adhesivelessmaterials may be employed in the first and second dielectric layers 20and 22.

The third dielectric layer 24 overlies the second dielectric layer 22and includes a continuous surface 50 extends between terminationopenings 52 at opposing ends of the third dielectric layer 24. Likewise,the fourth dielectric layer 26 underlies the first dielectric layer 20and includes a continuous surface 54 extending between terminationopenings 56 at opposing ends of the fourth dielectric layer 26. Thecontinuous surfaces 50, 54 of the respective third and fourth dielectriclayers 24, 26 closes the openings 40, 44 in the first and seconddielectric layers 20, 22 and seals the variable impedance material andthe gap 36 of the electrode.

In an illustrative embodiment, the third and fourth dielectric layers24, 26 are each fabricated from a polyimide dielectric film. In oneexemplary embodiment, the third dielectric layer 24 may be a 50 micronthick polyimide dielectric film including a 4 micron adhesive film tosecure the layers to one another, and the fourth dielectric film may bea 25 micron thick polyimide dielectric film including an 18 microncopper laminate. It is appreciated, however, that in alternativeembodiments, other dimensions of materials may be employed, and it isrecognized that other suitable electrical dielectric and insulationmaterials (polyimide and non-polyimide), may be employed. It is furthercontemplated that adhesiveless materials may be employed in the thirdand fourth dielectric layers 24 and 26.

The fifth dielectric layer 28 overlies the third dielectric layer 24,and in an exemplary embodiment may be a 25 micron thick polyimidedielectric film including an 18 micron copper laminate. The includessurface mount pads 60 formed on one surface thereof in a known manner.The termination pads 60 include termination openings 62. The fourthdielectric layer 26 also includes surface mount pads 64, and each of thepads 64 includes termination openings 66. In an exemplary embodiment thefourth and fifth dielectric layers 26, 28 are copper clad polyimidelaminates, and the copper is etched away from the layers to form thesurface mount pads 60, 62. It is understood, however, that the pads 60,62 could be alternatively formed in another known manner using, forexample, electroforming, printing, or deposition techniques.

When the layers 12, 20, 22, 24, 26, and 28 are stacked, the terminationopenings of the layers are aligned with one another and the innersurfaces of the termination openings are metallized with a conductivematerial, such as copper, on a vertical face 80 (FIG. 5) thereof tocomplete a conductive path between the surface mount pads 60, 64 andminor surfaces of the anchor portions 30, 32 of the electrode 12. Inother words, the metallized face 80 extends substantially perpendicularto the major planar surfaces of the electrode 12, and is tangential tothe vertical end faces (the minor surfaces) of the anchor portions 30,32. Castellated contact terminations are therefore provided on the endsof the device 10.

It is also recognized that at least some of the benefits of the presentinvention may be achieved by employing other termination structure thanin lieu of castellated contacts for connecting the transient voltagesuppression device 10 to an electrical circuit. Thus, for example,contact leads (i.e. wire terminations), wrap-around terminations, dippedmetallization terminations, and the like may be employed as needsdictate or as desired.

For purposes of describing an exemplary manufacturing process employedto fabricate the transient voltage suppression device 10, the dielectriclayers of the transient voltage suppression device 10 are referred toaccording to the following table:

Process FIG. 2 Layer FIG. 2 Layer Reference 1 First Dielectric Layer 202 Second Dielectric Layer 22 3 Third Dielectric Layer 24 4 FourthDielectric Layer 26 5 Fifth Dielectric Layer 28

Using these designations, FIG. 3 is a flow chart of an exemplary method100 of manufacturing the transient voltage suppression device 10 (shownin FIGS. 1 and 2).

The surface mount pads are formed 102 on layers 4 and 5 according to anyof the techniques described above or known in the art, and the openingsin layers 1 and 2 are formed 104 prior to assembly of the device asexplained below. Electrodes 12 are formed 105 independently fromdielectric layers, such as with the aforementioned electroformingprocess.

Layers 1, 2, and 4 are laminated 106 to one another with the electrode12 extending between layers 1 and 2, and with layer 4 closing theopening 40 in layer 4. Thus, as shown in FIG. 4, a subassembly is formedwherein the electrode path portions 34 and the electrode gap 36 areexposed and accessible within the opening 44 of layer 2, while layer 4closes the opening 40 in layer 1 proximate the electrode gap 36. Thevariable impedance material 70 (FIG. 5 a) is then introduced 107 to theopening 44 and fills each of the opening 44 in layer 2 and the opening40 in layer 1, so that the electrode path portions 34 and the electrodegap 36 are substantially surrounded by the variable impedance material70 both above and below the electrode path portions 34 and the gap 36,and while substantially filling the gap 36 with the variable impedancematerial 70.

Layers 3 and 5 are laminated 108 to one another to form a secondsubassembly for the device 10, and then the second subassembly islaminated to the first subassembly from step 106. When the first andsecond subassemblies are laminated to one another, the secondsubassembly closes the opening 44 in layer 2.

The termination openings are then formed 112 through the laminated firstand second subassemblies according to, for example, a known drillingprocess While transient voltage suppression devices 10 could bemanufactured singly according to the method thus far described, in anillustrative embodiment, transient voltage suppression devices 10 arefabricated collectively in sheet form and then separated or singulated114 into individual devices 10, as shown schematically in FIG. 6 whereina plurality of electrodes 12 including gaps 36 are formed on a largerpanel of material, and with the openings 44 and the termination openings120 outlined in phantom. Additionally, as can be seen in FIG. 6, theanchor portions 30, 32 of the electrodes include anchoring holes 122that serve to position and maintain the electrodes 12 relative to and inbetween layer 1 and layer 2. A cutting tool may be moved alongintersecting dicing lines 124, 126 to singulate the devices 10.

The devices 10 may be formed in a batch process, or with a continuousroll to roll lamination process to manufacture a large number oftransient voltage protection devices with minimal time.

The termination openings are plated or otherwise metallized 116 on avertical face 80 thereof (FIG. 5), either before or after thesingulation 114 of the devices, to complete the terminations 16 shown inFIG. 1.

It is contemplated that greater or fewer layers may be fabricated andassembled into the device 10 without departing from the basicmethodology described above. Using the above described methodology,transient voltage suppression devices may be efficiently formed usinglow cost, widely available materials in a batch process using relativelyinexpensive known techniques and processes. Additionally, themethodology provides greater process control in fewer manufacturingsteps than conventional transient voltage suppression deviceconstructions. As such, higher manufacturing yields may be obtained at alower cost.

In an exemplary embodiment, the variable impedance material 70 may beformulated from the following exemplary ingredients: conductiveparticles such as aluminum particles, a solvent such as Methyl n-AmylKetone (MnAK), a binder of polymer material such as flourosiliconerubber, insulator particles such as aluminum oxide, and filler particlesincluding an arc quenching material such as barium sulfate and insulatorspacer particles such as spherical borosilicate powders. The ingredientsare processed as follows according to the method 200 illustrated in FIG.7 to formulate the variable impedance material.

The conductive particles may be pre-coated 202 with an insulatingmaterial such as fumed silica, and the solvent and flourosilicone rubberare preferably premixed 204 in, for example, a planetary mixer for about24 hours to provide solvated rubber. The solvated rubber is then mixed206 with the pre-coated conductive particles and the filler materialincluding the arc quenching particles and the insulator spacerparticles, and the insulator particles in a mixer such as an overhead orbead mill for about 0.5 hours. Optionally, the mixture may be tumbled208, for example, for about 24 hours after mixing. Then, the materialmay be vulcanized 210 and preserved for use in manufacturing thetransient surge suppression devices 10.

Preferably, the variable impedance material 70 includes no more than 5%by weight of organic material, and thus for practical purposes issubstantially free of organic material. Also, the volume percent ratioof conductive particles to rubber is preferably between about 0.5 toabout 2, and more specifically between about 0.75 to about 1.5.

The choice of binder polymer and/or amount of filler in the variableimpedance material 70, or the degree of crosslinking or vulcanization ofthe material can be varied to change tensile properties of the materialand affect the thermal stress induced in the material when the materialis heated as a result of a voltage pulse during operation of the device10. By strategically selecting the binder polymer and/or amount offiller in the material, the degree of crosslinking or vulcanization ofthe material, the stress in the material in an overvoltage condition maybe controlled to produce desired switching properties of the materialbetween the on and off states. In general, the more stress that thedevice is subjected to, which is related to the binder polymer andamount of filler in the material formulation, the voltage at which thematerial changes from the off state to the on state is lowered. Thus,devices 10 having different sensitivities to overvoltage pulses may beprovided.

For greater endurance to high voltage transient pulses, an anti-trackingmaterial, such as iron oxide mixed with a polymer such as silicone, canbe added to the filler in the material formulation. By varying theamount of anti-tracking material in the formulation, insulatingproperties and anti-tracking properties of the device 10 during anovervoltage condition may accordingly be varied.

The above-described formulation and method is believed to provideconsistent variable impedance material for the device 10 at a lowercost, with less difficulty, and with a reduced processing time inrelation to known formulations of variable impedance materials. Suchformulation, as previously mentioned, produces a material exhibiting arelatively high impedance when subjected to voltage and/or current up toa predetermined threshold value, and exhibiting a relatively lowimpedance when subjected to voltage and/or current that exceeds thepredetermined threshold. By way of example only, when used with thedevice 10 in the manner described above, the device 10 has a triggervoltage of about 100 to 300 V that causes the material to change fromthe high resistance state to the low impedance state, produces a clampedvoltage during a transient voltage pulse event of about 20 to about 40V, exhibits a leakage current of less than about 1 nA in normaloperating conditions, and the material may withstand about 1000transient voltages or pulse events.

While an exemplary variable impedance material has been described thatmay be utilized in the device 10, it is understood that other knownvariable impedance materials may be employed that are fabricatedaccording to other known methods, while still achieving at least some ofthe advantages of the present invention. Likewise, while an exemplarytransient voltage suppression device has been described that utilizesthe variable impedance material produced according to the method 210, itis recognized that the variable impedance material could be used inother types of transient voltage protection devices. The foregoingdescription is therefore provided for illustrative purposes only and isnot intended to limit the device 10 to use with any particular variableimpedance material, or to limit the variable impedance material to usewith any particular device.

FIG. 8 is a perspective view of another embodiment of a transientvoltage suppression device 300 in accordance with another exemplaryembodiment of the present invention. The transient voltage suppressiondevice 300 is also believed to be manufacturable at a lower cost thanconventional transient voltage suppression device while providing higherproduction yields of satisfactory products.

The transient voltage suppression device 300 may have a layeredconstruction, described in detail below, and includes an electrode 302defining a conductive path enclosed in a number of dielectric layers 304as explained below. The transient voltage suppression device 300 mayhave a chip configuration as illustrated in FIG. 8. That is, the device300 may be generally rectangular in shape and includes a width W, alength L and a height H suitable for surface mounting of the device 300to a printed circuit board while occupying a small space. For example, Lmay be approximately 0.040 to 0.060 inches and W may be approximately0.020 to 0.030 inches, such that the transient voltage suppressiondevice occupies roughly the same area on a circuit board as otherelectrical chip components, including but not limited to chip fuses,chip resistors, and the like as those in the art may appreciate. H isapproximately equal to the combined thickness of the various layers 302and 304 employed to fabricate the transient voltage suppression device10. Notably, H is considerably less than either L or W to maintain a lowprofile of the transient voltage suppression device 300. It isrecognized, however, that actual dimensions of the device 10 may varyfrom the illustrative dimensions set forth herein to greater or lesserdimensions, including dimensions of more than one inch without departingfrom the scope of the present invention.

FIG. 9 is an exploded perspective view of transient voltage suppressiondevice 300 in a bulk fabrication assembly. Specifically, in an exemplaryembodiment, the transient voltage suppression device 300 is constructedessentially from four layers including an electrode 302 sandwichedbetween a first and second dielectric layers 306, 308 and a thirddielectric layer 310 overlying the second dielectric layer 308.

The electrode layer 302 is an electroformed, 3-20 micron thick copper ornickel foil which is fabricated and formed independently from the firstand second dielectric layers 306 and 308, the advantages of which aredescribed above, although it is understood that the electrode layer 302may be formed according to other known techniques in lieu ofelectroformation techniques if desired. Furthermore, other metals andconductive compositions and alloys may be used to form the electrodelayer 302.

The electrode layer 302 is formed into multiple elements each having theshape of a capital I with wider anchor portions 311 and 312 and arelatively narrow path portion 314 extending between the anchor portions311 and 312, thereby defining a conductive path between the first andsecond dielectric layers 306 and 308. A small gap 316, on the order ofseveral microns in an exemplary embodiment, interrupts the conductivepath through the path portions 314, and the variable impedance material320 is applied to the gap 316 in the manner explained below tointerconnect the path portions 314 of the electrode 302. The electrodegaps 316 are integrally formed into the image cast so that theelectroformed electrode is plated with the gap 316 already present orpre-formed, thereby eliminating separate manufacturing steps to form thegaps 316, together with related costs and difficulties. The gaps 316 maybe formed centrally in the electrode path portions 314 as shown in FIG.9, or may be formed elsewhere within the electrode layer 302 if desired.While one particular shape of the electrode layer 302 is illustrated inFIG. 9, it is understood that various other shapes of the shapes of theelectrode layer 302 may likewise be employed in other embodiments.

While electroforming of the electrode layer 302 in a manner separate anddistinct from the first and second dielectric layers 306 and 308 isbelieved to be advantageous, it is understood that the electrode layer302 may be alternatively formed by other methods while still obtainingsome of the advantages of the present invention. For example, theelectrode layer 302 may be an electro deposited metal foil applied tothe first dielectric layer 306 according to known techniques, includingother additive techniques such as screen printing and depositiontechniques, and subtractive techniques such as chemical etching and thelike as known in the art.

The first dielectric layer 306 underlies the electrode layer 302 andincludes circular shaped termination openings 330 underlying the anchorportions 311, 312 of the electrode layer 302, and more specifically, thetermination openings 330 are spaced from the gaps 316 in the electrodelayer 302. The termination openings 330 are filled with a conductivemetal such as copper, for example, to provide surface mount padterminations that directly engage and are in abutting contact with themajor planar surfaces of the electrode anchor portions 311, 312, as bestshown in FIG. 11.

It is recognized that at least some of the benefits of the presentinvention may be achieved by employing other termination structure inlieu of the surface mount pad terminations 340 for connecting thetransient voltage suppression device 300 to an electrical circuit. Thus,for example, contact leads (i.e. wire terminations), wrap-aroundterminations, dipped metallization terminations, castellated contactsand the like may be employed as needs dictate or as desired.

Referring back to FIG. 9, the second dielectric layer 308 overlies theelectrode layer 302 and includes circular shaped openings 350 overlyinga portion of the electrode layer path portions 314, and in particular,the gaps 316, of the electrode layer 302. As such, the path portions 314of the electrode layer 302 are exposed in the vicinity of the electrodegaps 316 within the openings 350. The openings 350 in the respectivesecond dielectric layer 308 expose the gaps 316 in the electrode anddefines receptacles above the gaps 316 for the introduction of thevariable impedance material 320 (also shown in FIG. 11). That is, theopenings 350 provide a confined location for the variable impedancematerial 320, and it may be accordingly be ensured that the variableimpedance material substantially surrounds and fills the gaps 316 toensure proper operation of the device 300. The third dielectric layer310, however, is solid and has no openings in the vicinity of theelectrode layer gaps 316.

In an illustrative embodiment, the first and second dielectric layers306, 308 are each fabricated from a commercially available polyimidedielectric film including an adhesive to secure the layers to oneanother and to the electrode layer 302. As one example, the firstdielectric layer 306 may be a commercially available 2 mil polyimidefilm, and the second dielectric layer 308 may be a commerciallyavailable 5 mil polyimide film.

It is appreciated, however, that in alternative embodiments, othersuitable electrical dielectric and insulation materials (polyimide andnon-polyimide), may be employed, and further that adhesiveless materialsmay be employed in the first and second dielectric layers 306 and 308.

The third dielectric layer 310 overlies the second dielectric layer 308and includes a continuous surface 360 with no openings therein. Thecontinuous surface 360 of the third dielectric layer 310 closes theopenings 350 in the second dielectric layer 308 and seals the variableimpedance material 320 and the electrode gasp 316.

In an illustrative embodiment, the third dielectric layer 310 isfabricated from a polyimide dielectric film. It is appreciated, however,that in alternative embodiments, other suitable electrical dielectricand insulation materials (polyimide and non-polyimide), may be employed,including an epoxy coating in lieu of a polyimide dielectric film.

When the layers 302, 306, 308, and 310 are stacked and secured togetherwith the variable impedance material 320 therein, the pads 340 areformed in the termination openings 330 of the first dielectric layer asshown in FIG. 10. FIG. 10 also schematically illustrates the electrodelayer 302, and dicing lines 380 and 382 to singulate the assembledlayers into discrete devices 300.

Once constructed, the device 300 operates substantially similar to thedevice 10 as described above.

For purposes of describing an exemplary manufacturing process employedto fabricate the transient voltage suppression device 300, thedielectric layers of the transient voltage suppression device 300 arereferred to according to the following table:

Process FIG. 9 Layer FIG. 2 Layer Reference 1 First Dielectric Layer 3062 Second Dielectric Layer 308 3 Third Dielectric Layer 310

Using these designations, FIG. 12 is a flow chart of an exemplary method400 of manufacturing the transient voltage suppression device 300.

The electrode layer is formed 402 independently from dielectric layers,such as with the aforementioned electroforming process, or anotherformation process known in the art, and layers 1 and 2 are laminated 404to one another with the electrode layer extending between layers 1 and2. Thus, a subassembly is formed wherein the electrode path portions 314and the electrode gaps 316 are exposed and accessible within theopenings 350 of layer 2, and the anchor portions 311, 312 of theelectrode layer are exposed within the termination openings 330 of layer1.

The surface mount pads are plated 406 within the openings in layer 1 incontact with the anchor portions 311, 312, and the variable impedancematerial 320 is introduced into the openings in layer 2 to substantiallysurround the electrode path portions 314 and fill the gaps 316. Thevariable impedance material may be the same or different from thevariable impedance material 70 described above.

Layer 3 and is then applied 408 to the layer 2 in a known manner, suchas a lamination process in the event that a polyimide material is usedfor layer 3, or by coating and curing in the case of an epoxy materialbeing used for layer 3. Layer 3 closes the openings in layer 2 and sealsthe variable impedance material therein.

Finally, the individual components or devices 300 are separated orsingulated 410 from one another along the dicing lines shown in FIG. 10.While transient voltage suppression devices 300 are described as beingfabricated collectively in sheet form and then separated or singulated410 into individual devices 300, the devices 300 could be individuallyfabricated if desired. The devices 300 may be formed in a batch process,or a continuous roll to roll lamination process to manufacture a largenumber of transient voltage protection devices with minimal time.

It is contemplated that greater or fewer layers may be fabricated andassembled into the device 300 without departing from the basicmethodology described above. Especially when the openings 330 and 350are pre-formed in layers 1 and 2, the method 400 may be completed in arelatively short period of time and with a reduced number of steps thanthe method 100 described above.

Using the above described methodology, transient voltage suppressiondevices may be efficiently formed using low cost, widely availablematerials in a batch process using relatively inexpensive knowntechniques and processes. Additionally, the methodology provides greaterprocess control in fewer manufacturing steps than conventional transientvoltage suppression device constructions. As such, higher manufacturingyields may be obtained at a lower cost.

FIGS. 13 and 14 illustrate another embodiment of a transient voltagesuppression device 500 that is essentially a combination of four devices10 described above in relation to FIGS. 1-6. Thus, in the illustratedembodiment, the device 500 provides four devices 10 in an in-linearrangement that may be connected to electronic circuitry in parallel toone another. While four devices 10 are integrated in the device 500shown in FIG. 13, it is appreciated that more or less devices 10 may beprovided in the device 500.

The device 500 may be constructed substantially as described above, withappropriate modifications of the dicing lines to form in-line devices500 in lieu of discrete devices 10. As shown in FIG. 14, the electrodepath portions 34 and the gaps 36 are exposed within the openings 44, 40in the first and second dielectric layers 22, 20, respectively.Introduction of the variable impedance material 70 is thereforesimplified, and for the reasons set forth above, the device 500 ismanufacturable at a lower cost with higher production yields than knowndevices.

In-line combinations of devices 300, described above in relation toFIGS. 8-11, could likewise be provided according the methodologydescribed above, with modification of the dicing lines to form in-linedevices instead of single or discrete devices.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

1. A transient voltage suppression device, comprising: a firstdielectric layer defining a first surface; an electrode extending on andin surface contact with the first surface and defining a conductivepath, the electrode including a gap that interrupts the conductive path;a variable impedance material substantially filling the gap in theelectrode; and a second dielectric layer overlying the electrode,wherein the electrode is sandwiched between the first and seconddielectric layers and wherein the variable impedance material is inabutting contact with at least a portion of an upper major surface andat least a portion of a bottom major surface of the electrode proximatethe gap.
 2. A transient voltage suppression device in accordance withclaim 1, wherein the electrode is formed independently of the first andsecond dielectric layers.
 3. A transient voltage suppression device inaccordance with claim 2, wherein the electrode is integrally formed withthe gap in an additive formation process.
 4. A transient voltagesuppression device in accordance with claim 3, wherein the electrodecomprises an electroformed thin foil.
 5. A transient voltage suppressiondevice in accordance with claim 4, wherein the electroformed thin foilis nickel.
 6. A transient voltage suppression device in accordance withclaim 1, further comprising castellated contact terminationsestablishing a conductive path to the at least one electrode on eitherside of the gap.
 7. A transient voltage suppression device in accordancewith claim 1, wherein each of the first and second dielectric layers arefabricated from a polymer material.
 8. A transient voltage suppressiondevice in accordance with claim 7, wherein the polymer material is apolyimide.
 9. A transient voltage suppression device comprising: a firstplanar dielectric layer; a second planar dielectric layer; at least onegenerally planar electrode extending between and in surface contact withat least one of the first planar dielectric layer and the second planardielectric layer, the electrode formed with a first portion, a secondportion and a gap that interrupts a conductive path between the firstportion and the second portion; and a variable impedance materialextending above the gap, below the gap, and filling the gap in theelectrode.
 10. The device of claim 9, wherein one of the first andsecond dielectric layer includes an opening, the variable impedancematerial contained in the opening.
 11. The device of claim 10, wherein:each of the first and second dielectric layers include a first majorsurface, a second major surface and a thickness between the first andsecond major surfaces; and the opening extends entirely through thethickness.
 12. The device of claim 10, wherein each of the first andsecond dielectric layers includes an opening, the variable impedancematerial contained in each opening above and below the gap.
 13. Thedevice of claim 12, wherein: each of the first and second dielectriclayers include a first major surface, a second major surface and athickness between the first and second major surfaces; and the openingin each of the first and second openings extends entirely through therespective thickness.
 14. The device of claim 9, wherein the opening isshaped to expose a distal end of each of the first and second portionsof the electrode proximate the gap.
 15. The device of claim 14, whereineach distal end includes an end surface, opposed major surfaces andopposed side surfaces.
 16. The device of claim 15, wherein the variableimpedance material surrounds the opposed major surfaces and the opposedside surfaces of each distal end.
 17. The device of claim 15, whereinthe opening is dimensioned to expose the opposed side surfaces of thedistal end.
 18. The device of claim 17, wherein the opening issubstantially circular.
 19. The device of claim 9, wherein the first andsecond dielectric layers are fabricated from a polymer material.
 20. Thedevice of claim 9, further comprising surface mount terminations. 21.The device of claim 9, wherein the at least one generally planarelectrode comprises a plurality of electrodes spaced apart from oneanother.
 22. The device of claim 9, wherein the electrode includes anupper major surface and a lower major surface, the lower major surfaceof the electrode being in surface contact with the at least one of thefirst planar dielectric layer and the second planar dielectric layer,and the variable voltage material being in surface contact with at leasta portion of the upper major surface of the electrode proximate the gap.23. The device of claim 22, wherein the other of the first planardielectric layer and the second planar dielectric layer includes anupper major surface and a lower major surface, the lower major surfaceof the other of the first planar dielectric layer and the second planardielectric layer being in surface contact with the variable voltagematerial at a location above the gap.
 24. The device of claim 22,wherein the variable voltage material is further in surface contact withat least a portion of the lower major surface of the electrode proximatethe gap.
 25. The device of claim 9, wherein the first and second planardielectric layers are each a polyimide dielectric film.
 26. A transientvoltage suppression device comprising: a laminated structure comprising:a first planar dielectric layer; a second planar dielectric layer; atleast one electrode extending between and in surface contact with thefirst dielectric layer and the second dielectric layer, the electrodeformed with a first portion, a second portion, and a gap that interruptsa conductive path between the first portion and the second portion; anda variable impedance material extending above the gap, below the gap,and filling the gap in the electrode.
 27. The device of claim 26,wherein the first portion and second portion of the electrode aregenerally coplanar.
 28. The device of claim 26, wherein each of thefirst portion and the second portion includes a distal end, the gapextending between the distal ends of the first and second portion. 29.The device of claim 28, wherein one of the first and second dielectriclayers includes an opening exposing each of the distal ends of theelectrode and the gap.
 30. The device of claim 29, wherein the openingis formed completely through a thickness of one of the first and seconddielectric layers.
 31. The device of claim 28, wherein the distal endseach include an end surface, opposed major surfaces, and opposed sidesurfaces proximate the end surface, the variable impedance materialcontacting at least the end surface, one of the opposed side surfacesand one of major surfaces of each distal end.
 32. The device of claim28, wherein the distal ends each include an end surface, opposed majorsurfaces, and opposed side surfaces proximate the end surface, thevariable impedance material surrounding the end surface, the opposedside surfaces and the opposed major surfaces of each distal end.
 33. Thedevice of claim 28, wherein the opening is substantially circular. 34.The device of claim 26, further comprising surface mount terminationsestablishing electrical connection to the respective first and secondportions of the electrode.
 35. The device of claim 26, wherein the atleast one electrode comprises a plurality of electrodes spaced apartfrom one another.
 36. The device of claim 26, wherein the electrodeincludes an upper major surface and a lower major surface, the lowermajor surface of the electrode in surface contact with one of the firstplanar dielectric layer and the second planar dielectric layer, and atleast a portion of the variable voltage material in surface contact withthe upper major surface of the electrode.
 37. The device of claim 26,wherein the first and second planar dielectric layers are each apolyimide dielectric film.
 38. A transient voltage suppression device,comprising: a first dielectric layer defining a first surface; anelectrode extending on and in surface contact with the first surface anddefining a conductive path, the electrode including a gap thatinterrupts the conductive path; a variable impedance materialsubstantially filling the gap in the electrode; and a second dielectriclayer overlying the electrode and defining a second surface, wherein thefirst and second surfaces are substantially coextensive; wherein theelectrode is sandwiched between the first and second dielectric layersand at least a portion of the electrode is in abutting contact with thefirst surface and the second surface; and wherein the variable impedancematerial extends below the first surface and above the second surface.39. The device of claim 38, wherein at least a portion of the variableimpedance material contacts one of the first and second surfaces. 40.The device of claim 38 further comprising surface mount terminations.41. The device of claim 40 wherein the surface mount terminationscomprise castellated contact terminations.
 42. A transient voltagesuppression device, comprising: a first dielectric layer defining afirst surface; an electrode extending on and in surface contact with thefirst surface and defining a conductive path, the electrode including agap that interrupts the conductive path; a variable impedance materialsubstantially filling the gap in the electrode; and a second dielectriclayer overlying the electrode and defining a second surface; wherein theelectrode is sandwiched between the first and second dielectric layersand at least a portion of the electrode is in abutting contact with thefirst surface and the second surface; wherein the variable impedancematerial extends below the first surface and above the second surface;and wherein at least a portion of the variable impedance materialcontacts both of the first and second surfaces.
 43. A transient voltagesuppression device, comprising: a first dielectric polymer film layerdefining a first surface; a second dielectric polymer film layerdefining a second surface coextensive with the first surface; anelectrode extending between the first and second surface and defining aconductive path, the electrode including a gap that interrupts theconductive path and the electrode including an upper major surface and alower major surface; and a variable impedance material substantiallyfilling the gap in the electrode, and the variable impedance materialextending above the first upper major surface of the electrode and belowthe lower major surface of the electrode proximate the gap; wherein theelectrode and the variable voltage material are contained between thefirst and second surface of the respective first and second dielectricpolymer film layers.